Process for the Production of Light Olefins from Synthesis Gas

Abstract

A new process for light-olefins production is disclosed. The process comprises the step of contacting syngas with a iron-based catalyst at a temperature in the range from 250° C. to 350° C. and at a pressure in the range from 10 bar to 40 bar. By so doing a production of light olefins with a selectivity of at least 80% is obtained.

1 . A process for the production of C2-C4 olefins comprising the step of contacting syngas with a iron-based catalyst at a temperature in the range from 250° C. to 350° C. and at a pressure in the range from 10 bar to 40 bar, wherein said iron-based catalyst includes nano-sized Fe particles as active component which are dispersed on a support or matrix, said nano-sized Fe particles being Fe nano-particles, Fe alloy nano-particles, nano-particles having an iron or iron alloy core and an iron-oxide shell or mixtures thereof. 
     
     
         2 . The process according to  claim 1 , wherein said nano-sized Fe particles have an iron or iron alloy core and an iron-oxide shell or mixtures thereof. 
     
     
         3 . The process according to  claim 1 , wherein said nano-sized Fe particles are substantially spherical and have a diameter less than 50 nm. 
     
     
         4 . The process according to  claim 2 , wherein the content of said nano-sized Fe particles is comprised between 1% and 5% by weight on the weight of the support or matrix. 
     
     
         5 . The process according to  claim 1 , wherein the catalyst includes a promoter of the catalytic activity chosen from elements, molecules/compounds and combinations thereof including: aluminium, potassium, calcium, magnesium, silicon, manganese and copper. 
     
     
         6 . The process according to  claim 5 , wherein the catalyst includes a Mn promoter. 
     
     
         7 . A process for the production of C2-C4 olefins comprising the step of contacting syngas with a iron-based catalyst at a temperature in the range from 250° C. to 350° C. and at a pressure in the range from 10 bar to 40 bar, wherein said iron-based catalyst includes iron and/or iron oxides particles as active component optionally arranged on a support or matrix and include a Mn promoter, as a promoter of the catalytic activity. 
     
     
         8 . The process according to  claim 1 , wherein said support or matrix is a metal oxide support or matrix chosen from the group including alumina, titania, silica, magnesium oxide, silica-alumina, ferrous materials such as magnetite, wustite, cordierite and mixtures thereof. 
     
     
         9 . The process according to  claim 8 , wherein said metal oxide support or matrix is magnetite. 
     
     
         10 . The process according to  claim 8 , wherein said contacting step is carried out at a temperature from 300° C. to 350° C. 
     
     
         11 . The process according to  claim 8 , wherein the syngas has a H2:CO molar ratio in the range from 1.5 to 2.5. 
     
     
         12 . The process according to  claim 8 , wherein the catalyst includes one or more promoters in a percentage of 0.1-5% by weight on the weight of the support or matrix. 
     
     
         13 . The process according to  claim 8 , further comprising the step of removing the reaction heat formed by the syngas conversion in a continuous or discontinuous way. 
     
     
         14 . The process according to  claim 3 , wherein said nano-sized Fe particles are substantially spherical and have a diameter between 15 and 25 mn. 
     
     
         15 . The process according to  claim 3 , wherein said nano-sized Fe particles are substantially spherical and have a diameter between 1 and 15 nm. 
     
     
         16 . The process according to  claim 6 , wherein the catalyst includes MnO and a K promoter. 
     
     
         17 . The process according to  claim 7 , wherein the catalyst includes MnO and a K promoter. 
     
     
         18 . The process according to  claim 7 , wherein said support or matrix is a metal oxide support or matrix chosen from the group including alumina, titania, silica, magnesium oxide, silica-alumina, ferrous materials such as magnetite, wustite, cordierite and mixtures thereof. 
     
     
         19 . The process according to  claim 8 , wherein the syngas has a H2:CO molar ratio around 2:1.